Light emitting device packages with improved heat transfer

ABSTRACT

Packages containing one or more light emitting devices, such as light emitting diodes (LEDs), are disclosed. In one embodiment, LED package can include a thermal element having improved solder reliability to improve heat dissipation capacity of the LED package. LED package can include a molded plastic body having one or more LEDs attached to one or more electrical elements. The LEDs can be connected to an upper surface of the thermal element. The thermal element can include a bottom surface which can extend further away in distance from a body of the LED package than a bottom surface of the electrical element. This configuration can result in an improved connection between the LED package and an external circuitry source, thereby increasing heat transfer ability of the LED package.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of and claims priority to co-pending U.S. patent application Ser. No. 12/825,075 filed Jun. 28, 2010, which relates and claims priority to and is a continuation-in-part application from these related matters: U.S. utility patent application Ser. No. 12/479,318, filed Jun. 5, 2009; U.S. design patent application Ser. No. 29/330,657, filed Jan. 12, 2010; U.S. design patent application Ser. No. 29/353,652 filed Jan. 12, 2010; U.S. design patent application Ser. No. 29/338,186 filed Jun. 5, 2009, and U.S. design patent application Ser. No. 29/360,791 filed Apr. 30, 2010, the entire contents of all of which are hereby incorporated by reference herein.

TECHNICAL FIELD

The subject matter disclosed herein relates generally to packages for light emitting devices. More particularly, the subject matter disclosed herein relates to light emitting device packages with improved heat transfer.

BACKGROUND

Light emitting devices, such as light emitting diodes (LEDs) for example, are often packaged within surface mounted device (SMD) housings. These housings are often made of plastic and are referred to as plastic leaded chip carriers (PLCCs). SMD housings can typically feature an LED connected to multiple metal leads. Portions of the leads may be molded within a plastic body, while other portions may protrude and extend outside of the plastic body. The molded plastic body can define a reflector for enhanced light emission and can be coated with an encapsulant containing a phosphor, such as yttrium aluminum garnet (YAG) for obtaining light having a desired wavelength spectrum. The body of the SMD housing can also comprise a ceramic material. The metal leads of the leadframe package serve to as a channel for supplying the LED with electrical power and, at the same time, may act to draw heat away from the LED chip.

Heat is generated by the LED when power is applied to the LED to produce light. The portion of the leads that can extend out from the package body can connect to circuits external to the leadframe package, for example those on a printed circuit board (PCB). Some of the heat generated by the LED may be dissipated by the plastic package body; however, it is desirable for most of the heat to be drawn away from the LED via the metal components, or other elements of high thermal conductivity. To increase the heat dissipating capacity of an LED package, a heat transfer material or substrate such as a heat slug may be introduced into the package. Standard soldering processes such as lead-free reflow are used for assembly of the LED packages to external sources, such as PCBs. Once soldered, the heat slug can draw heat from the LED chip to an external source, thus increasing the heat dissipating capacity of the LED package. However, conventional package designs utilize designs wherein the external surface of the heat slug is flush with an external surface of the metal leads on a side of the package in which the surfaces will become attached to the PCB. To be adequate, the metal leads need only establish an electrical contact with the PCB. However, adequate contact between the PCB and heat sink is more difficult because in order to ensure adequate thermal transfer, ideally the entire bottom surface of the heat sink needs wetted by the solder to minimize voids. Current LED package designs can result in the surface of the heat sink being inadequately wetted, thus inadequately soldered to the PCB and thereby decreasing both reliability and heat dissipation of the LED package. If not adequately wetted, voids can exist between the bottom surface of the heat transfer material and the PCB, thus resulting in poor heat transfer as well as heat dissipation problems.

Consequently, there remains a need for improved light emitting device packages that overcome or alleviate shortcomings of prior art light emitting device packages.

SUMMARY

In accordance with this disclosure, light emitting device packages are provided with improved heat transfer. It is, therefore, an object of the present disclosure herein to provide light emitting device packages with both improved solder reliability and improved heat dissipating capacity for improving heat transfer between a backside of the LED package and a printed circuit board (PCB) or other receiving substrate.

These and other objects of the present disclosure as can become apparent from the disclosure herein are achieved, at least in whole or in part, by the subject matter described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present subject matter including the best mode thereof to one of ordinary skill in the art is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which:

FIG. 1 illustrates a perspective top view of an embodiment of an LED package with a heat transfer material according to the subject matter herein;

FIG. 2A illustrates a side view of an embodiment of an LED package with a heat transfer material according to FIG. 1;

FIG. 2B illustrates a side view of an embodiment of a mounted LED package according to the subject matter herein;

FIG. 2C illustrates a side view of an embodiment of a mounted LED package according to the subject matter herein;

FIG. 2D illustrates a side view of an embodiment of a mounted LED package according to the subject matter herein;

FIG. 3A illustrates a perspective bottom view of an embodiment of an LED package with a heat transfer material according to the subject matter herein;

FIG. 3B illustrates a perspective bottom view of an embodiment of an LED package with a heat transfer material according to the subject matter herein;

FIG. 4 illustrates a perspective top view of an embodiment of an LED package with a heat transfer material according to the subject matter herein;

FIG. 5A illustrates a side view of an embodiment of an LED package with a heat transfer material according to FIG. 4;

FIG. 5B illustrates a side view of an embodiment of a mounted LED package according to the subject matter herein;

FIG. 5C illustrates a side view of an embodiment of a mounted LED package according to the subject matter herein;

FIG. 5D illustrates a side view of an embodiment of a mounted LED package according to the subject matter herein;

FIG. 5E illustrates a side view of an embodiment of an LED package according to the subject matter herein;

FIG. 6A illustrates a perspective bottom view of an embodiment of an LED package with a heat transfer material according to the subject matter herein;

FIG. 6B illustrates a perspective bottom view of an embodiment of an LED package with a heat transfer material according to the subject matter herein;

FIG. 6C illustrates a perspective bottom view of an embodiment of an LED package with a heat transfer material according to the subject matter herein;

FIG. 7 illustrates a perspective top view of an embodiment of an LED package with a heat transfer material according to the subject matter herein;

FIG. 8 illustrates a perspective bottom view of an embodiment of an LED package with a heat transfer material according to FIG. 7;

FIG. 9A illustrates a side view of an embodiment of an LED package with a heat transfer material according to FIG. 7;

FIG. 9B illustrates a side view of an embodiment of a mounted LED package according to the subject matter herein;

FIG. 10A illustrates a side view of an embodiment of an LED package with a heat transfer material according to the subject matter herein;

FIG. 10B illustrates a top perspective view of an embodiment of an LED package according to FIG. 10A;

FIG. 10C illustrates a bottom perspective view of an embodiment of an LED package according to FIG. 10A; and

FIG. 10D-10F illustrate bottom perspective views of embodiments of an LED package with grooves according to the subject matter herein.

DETAILED DESCRIPTION

Reference will now be made in detail to possible embodiments of the subject matter herein, one or more examples of which are shown in the figures. Each example is provided to explain the subject matter and not as a limitation.

In fact, features illustrated or described as part of one embodiment can be used in another embodiment to yield still a further embodiment. It is intended that the subject matter disclosed and envisioned herein covers such modifications and variations.

As illustrated in the various figures, some sizes of structures or portions are exaggerated relative to other structures or portions for illustrative purposes and, thus, are provided to illustrate the general structures of the present subject matter. Furthermore, various aspects of the present subject matter are described with reference to a structure or a portion being formed on other structures, portions, or both. As will be appreciated by those of skill in the art, references to a structure being formed “on” or “above” another structure or portion contemplates that additional structure, portion, or both may intervene. References to a structure or a portion being formed “on” another structure or portion without an intervening structure or portion are described herein as being formed “directly on” the structure or portion. Similarly, it will be understood that when an element is referred to as being “connected”, “attached”, or “coupled” to another element, it can be directly connected, attached, or coupled to the other element, or intervening elements may be present. In contrast, when an element is referred to as being “directly connected”, “directly attached”, or “directly coupled” to another element, no intervening elements are present.

Furthermore, relative terms such as “on”, “above”, “upper”, “top”, “lower”, or “bottom” are used herein to describe one structure's or portion's relationship to another structure or portion as illustrated in the figures. It will be understood that relative terms such as “on”, “above”, “upper”, “top”, “lower” or “bottom” are intended to encompass different orientations of the device in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, structure or portion described as “above” other structures or portions would now be oriented “below” the other structures or portions. Likewise, if devices in the figures are rotated along an axis, structure or portion described as “above”, other structures or portions would now be oriented “next to” or “left of” the other structures or portions. Like numbers refer to like elements throughout.

Light emitting devices according to embodiments described herein may comprise III-V nitride (e.g., gallium nitride) based light emitting diodes (LEDs) or lasers fabricated on a silicon carbide substrate, such as those devices manufactured and sold by Cree, Inc. of Durham, N.C. Such LEDs and/or lasers may also be configured to operate such that light emission occurs through the substrate in a so-called “flip chip” orientation or by conventional wirebonding techniques.

Referring now to FIGS. 1-10F, FIG. 1 illustrates a top perspective view of one embodiment of a light emitting device package, for example an LED package, generally designated 10. Corresponding side and bottom perspective views of LED package 10 are illustrated in FIGS. 2A-2C and 3A-3B. FIGS. 2B-2C illustrate LED package 10 engaging an external source or substrate, for example a printed circuit board (PCB) 30. LED package 10 can comprise a body 18 housing one or more LED chips 12 a attached to an upper surface of a thermal element. An electrostatic discharge (ESD) protection device 12 b can be part of the LED package 10 and mounted to a top surface of an electrical element, for example a metal lead 20 a. For example, ESD protection device 12 b can comprise a Zener diode, ceramic capacitor, transient voltage suppression (TVS) diode, multilayer varistor, a Shottky diode and/or any other ESD device known in the art.

Body 18 can comprise a body selected from a group of materials consisting of molded plastic, polymeric, thermoset plastic, thermoplastic, ceramic, nylon, liquid crystal polymer (LCP), or polyvinyl chloride (PVC) wherein body 18 can be disposed around thermal and electrical elements. The thermal element can comprise a heat transfer material or substrate 14, such as for example a heat slug disposed on a bottom floor of a reflector cavity 16 of the package body 18, and reflector cavity 16 can be coated with an encapsulant E. Encapsulant E can comprise any suitable material known in the art and can optionally comprise a phosphor or a lumiphor to interact with light emitted by the LED chips 12 a and responsively emit light of a different wavelength spectrum. For illustration purposes, encapsulant E is shown to fill reflector cavity 16 essentially flush with an upper surface of the body. Encapsulant E however, may be filled to any suitable level within the reflector cavity 16 or even exceed and extend above reflector cavity 16 as known in the art.

The thermal element can comprise a thermal heat transfer material 14, and can comprise a metal or any other suitable thermally conducting material known in the art. Heat transfer material 14 can be formed integrally as one piece or, as illustrated in FIGS. 3A and 3B, may comprise several portions, for example a protruding portion 14 a attached to and extending from a base portion 14 b of thermally conducting material assembled together as known in the art. Heat transfer material 14 as well as all the other heat transfer materials identified and described further herein can be any suitable type of heat transfer device. In one aspect, heat transfer material 14 as well as all the other heat transfer materials identified and described further herein can be an intermediary thermal structure for transferring heat to another structure such as a heat transfer layer or a heat sink for further heat dissipation. In this aspect, heat transfer material 14 as well as all the other heat transfer materials identified and described further herein can be a thermal structure with limited heat capacity and capable of heating up quite quickly if not effectively connected thermally to a further heat transfer device such as an actual heat sink.

Wirebonding the LED chips 12 a and ESD device 12 b can electrically connect the LED chips 12 a and ESD device 12 b to electrical elements. Heat transfer material 14 can be electrically isolated from electrical elements 22 a and 22 b, for example isolated from metal leads 20 a and 20 b, by insulating portions of body 18. An exposed lower surface 26 of heat transfer material 14 can extend from a bottom surface 19 of body 18. Heat transfer material 14 can conduct heat away from LED chips 12 a and LED package 10 allowing improved heat dissipation therefrom.

Electrical elements can comprise metal leads 20 a and 20 b formed from a leadframe which can serve as anode and cathode connections supplying the LED chips 12 a with current sufficient to cause light emission. Leads 20 a and 20 b can comprise a metal or any other suitable electrically conducting material known in the art. Vertical portions 25 a and 25 b of leads 20 a and 20 b, respectively, can extend from body 18 at lateral exterior side walls of body 18. Vertical portions 25 a and 25 b can extend vertically in a downward direction from body 18 and can also comprise a portion orthogonal to linear portions 24 a and 24 b of leads 20 a and 20 b. Linear portions 24 a and 24 b can extend outwards in a linear direction and in opposite directions away from the body 18 of the LED package 10. Vertical portions 25 a and 25 b can be located along exterior sides disposed between an upper surface of the body 18 having the reflector cavity 16 and a bottom surface 19 of the body 18. Vertical portions 25 a and 25 b and linear portions 24 a and 24 b can each comprise a bend such as bend 27 disposed therebetween. That is, each bend 27 provides a transitioning area wherein vertical portions 25 a and 25 b transition perpendicularly into linear portions 24 a and 24 b, respectively. This arrangement of lead components can be referred to as a “gull wing” type lead component. Each bend 27 can be formed before or more typically after formation of body 18 structure. Linear portions 24 a and 24 b can be electrically connected to form an electrical contacts with an external source, such as for example, a PCB 30 as illustrated by FIGS. 2B and 2C. The gull wing type lead component can be difficult to manufacture, as the body of the package is prone to damage when the package is subjected to bending forces required to induce the linear portions of the leads to bend out away from the body 18 and each other.

Referring now to FIG. 2B, linear portions 24 a and 24 b of leads 20 a and 20 b, as well as a bottom surface 26 of heat transfer material 14 can be mounted to the PCB 30 using standard soldering techniques wherein solder 32 wets bottom surfaces of both the thermal and electrical elements. Such techniques can comprise for example, soldering PCB 30 in a reflow oven or placing PCB 30 on a hotplate. Any suitable solder material known in the art and capable of securing thermal and electrical elements, that is heat transfer material 14 and linear portions 24 a and 24 b of leads 20 a and 20 b, to PCB 30 may be used. For example, a solder 32 can comprise a solder paste of gold, tin, silver, lead and/or copper (Au, Sn, Ag, Pb, and/or Cu), reflow solder flux, and/or any combination thereof. For example, Sn 96.5/Ag 3.0/Cu 0.5 is a common Pb-free solder as is Sn 95.5/Ag 3.8/Cu 0.7.

As further illustrated by FIGS. 2A-2D, heat transfer material, generally designated 14, can comprise bottom surface 26 which extends further away from the body 18 at a greater distance than a distance from the body 18 to bottom surfaces 28 a and 28 b of linear portions 24 a and 24 b, respectively, of leads 20 a and 20 b when package 10 is mounted, for example by soldering, to the PCB 30. Thus, bottom surface 26 of heat transfer material 14 can be said to be extending a distance to a first plane P1 which is lower than a second plane P2 which is the plane of the bottom surfaces 28 a and 28 b of linear portions 24 a and 24 b of leads 20 a and 20 b. As shown by FIGS. 2A-2D, the bottom surfaces 28 a and 28 b of the electrical element extend away from the body a first distance, and the bottom surface 26 of the thermal element extending away from the body a second distance, and the second distance can be greater than the first distance. In one aspect, a suitable distance between P1 to P2 can, for example only and without limitation, be from slightly above 0 μm to greater than 100 μm. In other embodiments, the distance from P1 to P2 can be from 25 μm to 50 μm, 50 μm to 100 μm, or greater than 100 μm.

As illustrated by FIG. 2B, once wetted by solder 32, any gap between the thermal element, that is, a gap 36 between bottom surface 26 of heat transfer material 14 and the PCB 30 will be smaller than a gap 34 between the electrical elements, that is, the bottom surfaces 28 a and 28 b of linear portions 24 a and 24 b of leads 20 a and 20 b and PCB 30. Having heat transfer material 14 in this configuration can increase the likelihood that the solder 32 will wet the entire bottom surface 26 of heat transfer material 14 and can allow formation of an adequate thermal contact between the LED package 10 and PCB 30. Upon solidification of the solder 32, the thermal contact between heat transfer material 14 and PCB 30 can comprise a solder joint that is essentially free of voids, thereby being more reliable. This can increase the likelihood of obtaining better heat transfer from heat transfer material 14 to PCB 30. For example, if LED package 10 were to be sheared from PCB 30, a footprint of the solder joint on the backside of the package and PCB 30 would preferably be essentially free of voids. A small number, or substantially zero voids indicates better wetting of the thermal element, and a better, more reliable thermal contact between heat transfer material 14 of LED package 10 and PCB 30. Bottom surface 26 of heat transfer material 14 as well as bottom surfaces 28 a and 28 b of portions of leads 24 a and 24 b are thus all wetted by solder 32 and connected to the PCB 30 upon solidification of the solder 32.

Also illustrated by FIGS. 2B-2D, PCB 30 can be an intermediate substrate located above a heat transfer layer 33 and a heat sink 35. Heat can dissipate away from LED package 10 by moving in a path and pass from the heat transfer material 14 into solder 32 and then into the PCB 30. Heat can then pass from PCB 30 and into heat transfer layer 33 which can comprise any material known in the art that is thermally conductive. Heat continues on a path which passes from heat transfer layer 33 into heat sink 35 which can pass heat into ambient air for example. Heat sink 35 can comprise any material known in the art capable of conducting heat, and which ideally would not increase in temperature when heat is applied.

FIGS. 2A-2D also illustrate bottom surface 26 of heat transfer material 14 which can be disposed in a recess 38 that can be formed in or part of the bottom surface 19 of body 18. Recess 38 can allow the overflow of solder (such as solder 32) and/or flux to move into recess 38. This feature can eliminate or reduce the need to clean residue left behind by the attachment process, for example, using a “no-clean” solder. Recess 38 can also allow more access for solvents to remove flux after the reflow process if using for example, a “clean” solder which must undergo a cleaning process. Because of process variability, the amount of solder and/or flux that is dispersed to connect components, such as heat transfer material 14 and PCB 30, can vary significantly. As the solder and/or flux can be very difficult to remove from substrates such as PCBs, recess 38 provides a space for any excess solder and/or flux to flow into thereby producing the area(s) needing cleaning afterwards. Exposed portions of heat transfer material 14 can be located within recess 38. For example, FIG. 2A shows exposed portions 1-3, 26, and 5-7 of heat transfer material 14. Each exposed portion is an external surface of heat transfer material 14, which can be formed integrally as one piece, or formed from more than one portion such as protruding portion 14 a and base portion 14 b illustrated in FIGS. 3A-3B. As illustrated, at least one of the exposed portions 1-3, 26, and 5-7 of heat transfer material 14 can be located above the bottom surface 28 a and 28 b of linear portions 24 a and 24 b of leads, that is located above P2 while at least one of the exposed portions 1-3, 26, and 5-7 can be located below P2.

More specifically, in high-temperature metal joining processes including soldering, flux can have a primary purpose of preventing oxidation of the base and filler materials. Flux is a substance which is nearly inert at room temperature, but which becomes strongly reducing at elevated temperatures, thus preventing the formation of metal oxides. Flux also acts as a wetting agent in the soldering process, reducing surface tension of the molten solder and causing it to better wet the components being joined. Fluxes can comprise water-soluble fluxes so-called “clean” fluxes that do not require any volatile organic compounds for removal and “no-clean” fluxes which are mild enough to not require removal at all. Some fluxes are formulated to result in a residue which is not significantly corrosive, but cleaning is still preferred. As such, it is advantageous that recess 38 provides a space for any excess solder and/or flux to flow into thereby producing the areas needing cleaning afterwards.

Referring to FIGS. 2C and 2D, PCB 30 can optionally comprise a notch 31 that can extend either partially (FIG. 2C) or entirely through (FIG. 2D) PCB 30. Notch 31 can facilitate for example, the alignment of heat transfer material 14 or any other heat transfer materials when mounting to a thermally conductive element of an external substrate, such as a PCB 30. Other features correspond to FIGS. 2A and 2B described above. At least a portion of heat transfer material 14 can extend into and at least partially or completely fill notch 31. That is, bottom surface 26 of heat transfer material 14 can substantially correspond to a surface of notch 31 and sides of at least a portion of heat transfer material 14 can be smaller than or substantially correspond in width to a width W of notch 31. Solder 32 can still flow around heat transfer material 14 to connect heat transfer material 14 to PCB 30. Plane P1 of heat transfer material 14 can extend from P2 a distance required to fill notch 31. For example, the distance can be from slightly above 0 μm to 100 μm, from 25 μm to 50 μm, or greater than 100 μm. As illustrated by FIG. 2D, notch 31 can extend and comprise a depth entirely through PCB 30 wherein heat transfer material 14 can thermally contact and connect any suitable further heat dissipating structure or structures, such as heat transfer layer 33. This can further improve heat dissipation from the LED package 10. For example, heat transfer material 14 can have at least a portion of bottom surface 26 soldered directly to heat transfer layer 33 while at least a portion of exposed portions 1-3 and 5-7 (FIG. 2A) of heat transfer material 14 can be soldered to PCB 30. In FIGS. 2C and 2D, heat can advantageously pass away from the LED package 10 and into intermediate components comprising heat transfer material 14, PCB 30, and heat transfer layer 33 before ultimately passing into heat sink 35. Alternatively, heat transfer material 14 can thermally contact and connect with heat sink 35 directly without contacting an intermediate transfer layer such as intermediate heat transfer layer 33.

Referring now to FIGS. 3A and 3B, these figures illustrate a perspective bottom view of the features opposing the top view illustrated by FIG. 1. For example, heat transfer material 14 can be formed integrally as one piece, or may be formed from several portions including protruding portion 14 a and base portion 14 b. Base portion 14 b of the thermal element extends from body 18. Protruding portion 14 a attaches to base portion 14 b and can be dimensionally smaller on the sides than base portion 14 b although it can be of a greater height or thickness than base portion 14 b as illustrated by FIG. 3B. Protruding portion 14 a and base portion 14 b can comprise any size and/or shape known in the art and are not limited hereto. Having a protruding portion 14 a from a base portion 14 b allows improved wetting as solder can more fully wet the surface of protruding portion 14 a. Thus, a more uniform solder joint, or thermal connection, can form between the LED package 10 and PCB 30. Heat transfer material 14 can be disposed within recess 38 and linear portions 24 a and 24 b of electrical elements can be seen extending outwards from the body in a direction away from each other. FIG. 3A illustrates a view wherein the distance between planes P1 and P2 can be as illustrated by FIG. 2A and can, for example only and without limitation, range from slightly above 0 μm to 50 μm, 25 μm to 50 μm, or 50 μm to 100 μm. FIG. 3B illustrates a larger heat transfer material wherein the distance between planes P1 and P2 is greater and can be greater than 100 μm, and could be useful for applications as illustrated by FIGS. 2C and 2D. For applications utilizing distances greater than about 100 μm, notch 31 can be useful for alignment purposes and to facilitate adequate contact between the thermal element, heat transfer material 14, and the PCB 30.

FIGS. 4-6C illustrate views of another embodiment of an LED package, generally designated as 40, having features which can correspond substantially in form and function to those of FIGS. 1-3B. For example, LED package 40 can comprise one or more LED chips 42 attached to an upper surface of a thermal element. One or more ESD devices (not shown) may be attached to an upper surface of an electrical element as well. Thermal element can comprise a heat transfer material generally designated 44 made of a thermally conducting material and disposed on a bottom floor of a reflector cavity 46 of a package body 48. As previously described, body 48 can comprise any suitable material known in the art, and can be formed about, thereby encasing thermal and electrical elements. Reflector cavity 46 can be coated with encapsulant E which can optionally containing a phosphor or lumiphor. For illustration purposes encapsulant E is shown as substantially flush with an upper surface of the body 48 and the top of the reflector cavity 46, but it may be filled to any level above or below the top of the reflector cavity 46.

LED chips 42 can electrically connect to electrical elements, for example metal leads 50 a and 50 b formed from a leadframe which serve as anode and cathode components supplying current to the LED chips 42. Heat transfer material 44 can be electrically isolated from leads 50 a and 50 b by insulating portions 52 a and 52 b of the body 48. Heat transfer material 44 can conduct heat away from the LED chips 42 and allow heat to dissipate therefrom. Portions 55 of leads 50 a and 50 b can extend from the body 48 at a lateral exterior face and transition into linear portions 54 a and 54 b which can turn in towards each other and face the thermal element when mounted to an external source, for example a PCB 60. Extending portions 55 of leads 50 a and 50 b can extend from the lateral exterior faces of body 48 and can comprise a first bend. Extending portions 55 can bend to form vertical portions 57 a and 57 b of leads 50 a and 50 b which can be orthogonal to linear portions 54 a and 54 b, respectively. Second bending portions 53 can be located along a central axis beneath extending portions 55 and can perpendicularly transition the vertical portions 57 a and 57 b into the linear portions 54 a and 54 b, respectively, of leads 50 a and 50 b. This configuration can be referred to as a “J-bend” type lead component. Linear portions 54 a and 54 b form electrical contacts with the PCB 60 upon soldering. Linear portions 54 a and 54 b can electrically connect to the PCB 60 using standard soldering processes as previously described. As with the gull wing type lead component, the J-bend type lead component can be difficult to manufacture, as the body of the package is prone to damage when the package is subjected to bending forces required to induce the linear portions of the leads to bend in to face each other.

As illustrated in FIGS. 5A-5E, heat transfer material 44 can comprise an exposed, bottom surface 56 which can extend a greater distance away from body 48 of LED package than a distance from body 48 to bottom surfaces 58 a and 58 b of linear portions of leads 54 a and 54 b, respectively, when package 40 is mounted, for example by soldering, to the PCB 60. Thus, bottom surface 56 of heat transfer material 44 extends to a lower plane P1 than a plane P2 of which bottom surfaces 58 a and 58 b can extend to. As shown by FIGS. 5A-5E, the bottom surfaces 58 a and 58 b of the electrical element extend away from the body a first distance, and the bottom surface 56 of the thermal element can extend away from the body to a second distance. The second distance can be greater than the first distance. A gap 66, which can exist or form between bottom surface 56 of heat transfer material 44 and PCB 60, can be smaller than a gap 64 between the bottom surfaces 58 a and 58 b of leads 54 a and 54 b and PCB 60. At least one of exposed portions 1-3, 56, and 5-7 of heat transfer material 44 can be located above the bottom surfaces 58 a and 58 b of the linear portions 54 a and 54 b, respectively, of the leads, located above P2. Additionally, at least one of exposed portions 1-3, 56, and 5-7 of heat transfer material 44 can be located below the bottom surfaces 58 a and 58 b of the linear portions 54 a and 54 b, respectively, of the leads, located below P2. As described earlier, having heat transfer material 44 in this configuration can increase the likelihood that the entire surface 56 of heat transfer material 44 will be wetted by solder 62, which can allow formation of a good thermal contact between heat transfer material 44 and PCB 60. This configuration can allow LED package 40 to adapt to process variably in the amount of solder dispersed. Once the solder 62 solidifies, the thermal contact can comprise a solder joint that is more reliable because it can be a joint essentially free of voids between LED package 40 and PCB 60. This can ensure improved heat transfer from the bottom surface 56 of heat transfer material 44 to the PCB 60. In addition to bottom surface 56 of heat transfer material 44, bottom surfaces 58 a and 58 b of linear portions 54 a and 54 b of the leads can be wetted by solder 62 to form electrical contacts with PCB 60 once solder 62 solidifies.

Also illustrated by FIGS. 5B-5D, PCB 60 can comprise an intermediate substrate disposed above a heat transfer layer 63 and a heat sink 65. Heat can dissipate away from the LED package 40 by moving in a path and pass from heat transfer material 44 into solder 62 and then into PCB 60. Heat can then pass from PCB 60 and into heat transfer layer 63 which can comprise any material known in the art that is thermally conductive. Heat continues on a path which passes from heat transfer layer 63 into heat sink 65 which can pass heat into ambient air for example. Heat sink 65 can comprise any material known in the art capable of conducting heat, and which ideally would not increase in temperature when heat is applied.

Referring to FIGS. 5C-5D, PCB 60 can comprise a notch 61 That can extend either partially (FIG. 5C) or entirely (FIG. 5D) through notch 61. Notch 61 can facilitate for example, the alignment of heat transfer material 14 or any other heat transfer materials when mounting to an external substrate, such as a PCB 60. Other features correspond to FIGS. 5A and 5B described earlier. Heat transfer material 44 can be formed integrally in one piece or can comprise more than one portions, for example a protruding portion 44 a and a base portion 44 b. At least a portion of heat transfer material 44 can extend into notch 61. That is, bottom surface 56 of heat transfer material 44 can substantially correspond to surface of notch 61 and sides of at least a portion of heat transfer material 14 can substantially correspond in width to a width W of notch 61. Solder 62 can still flow around heat transfer material 44 to connect heat transfer material 44 to PCB 60. Plane P1 of heat transfer material 44 can extend from P2 a distance required to substantially engage notch 61, which can, for example and without limitation, be greater than 100 μm. For applications utilizing distances greater than about 100 μm, notch 61 can be useful for alignment purposes and to facilitate adequate contact between the thermal element, heat transfer material 44, and the PCB 60.

Referring to FIG. 5D, notch 61 can extend and comprise a depth entirely through PCB 60 wherein heat transfer material 44 can be connected directly with heat transfer layer 63. This can further improve heat dissipation from the LED package 40. For example, heat transfer material 44 can have bottom surface 56 soldered directly to heat transfer layer 63 while at least a portion of exposed portions 1-3 and 5-7 (FIG. 5A) of heat transfer material 44 can be soldered to PCB 60. In FIGS. 5C and 5D, heat can advantageously pass away from LED package 40 and into intermediate components such as heat transfer material 44, PCB 60, and heat transfer layer 63 before ultimately passing into heat sink 65. Alternatively, heat transfer material 44 can thermally contact and connect with heat sink 65 directly without contacting an intermediate transfer layer such as intermediate heat transfer layer 63.

FIG. 5E illustrates bottom surface 56 of heat transfer material 44 which can be disposed in a recess 59 that can be formed in or part of the bottom surface 49 of body 48. Recess 59 can allow the overflow of solder (such as solder 62 in FIGS. 5B and 5C) and/or flux to move into recess 59. This feature can eliminate or reduce the need to clean residue left behind by the attachment process. Because of process variability, the amount of solder and/or flux that is dispersed to connect components, such as heat transfer material 44 and PCB 60, can vary significantly. As the solder and/or flux can be very difficult to remove from substrates such as PCBs, recess 59 provides a space for any excess solder and/or flux to flow into thereby producing the area(s) needing cleaning afterwards. Exposed portions of heat transfer material 44 can be located within recess 59. For example, FIG. 5A shows exposed portions 1-3, 56, and 5-7 of heat transfer material 44. Each exposed portion is an external surface of heat transfer material 44, which can be formed integrally as one piece, or formed from more than one portion such as protruding portion 44 a and base portion 44 b illustrated in FIGS. 6A-6C. As illustrated, at least one of the exposed portions 1-3, 56, and 5-7 of heat transfer material 44 can be located above the bottom surface 58 a and 58 b of linear portions 54 a and 54 b of leads, that is located above P2 while at least one of the exposed portions 1-3, 56, and 5-7 can be located below P2.

Referring now to FIGS. 6A-6C, these figures illustrate a perspective bottom view of the features opposing the top view illustrated by FIG. 4. For example, heat transfer material 44 can be formed integrally or by assembling one or more portions together, for example protruding portion 44 a and base portion 44 b. Linear portions 54 a and 54 b of electrical elements can be seen as extending in towards the body and towards heat transfer material 44 to face each other. Base portion 44 b of the thermal element extends from the body 48. Protruding portion 44 a attaches to base portion 44 b and can be dimensionally smaller on the sides than base portion 44 b although it can be of a greater height or thickness than base portion 44 b as illustrated by FIG. 6B. Protruding portion 44 a and base portion 44 b can comprise any size and/or shape known in the art and are not limited hereto. By having a protruding portion 44 a from a base portion 44 b, improved wetting can be achieved as solder can more fully wet the surface of the protruding portion 44 a. Thus, a more uniform solder joint, or thermal connection, can form between the LED package 40 and PCB 60. FIG. 6A further illustrates a view wherein the distances between planes P1 and P2 (seen in FIG. 5A) is more likely a range between 1 and 50 μm. FIG. 6B illustrates a view wherein the distances between planes P1 and P2 is greater, and more likely greater than 100 μm, and could be useful for applications as illustrated by FIGS. 5C and 5D. FIG. 6C illustrates a view wherein a recess 59 can be formed in or part of the bottom surface 49 of body 48 as seen in FIG. 5E.

FIGS. 7-9B illustrate top perspective, bottom perspective, and side views of another embodiment of an LED package, generally designated 70, which has features that can substantially correspond in form and function to the embodiments shown by FIGS. 1-6C. For example, LED package 70 can comprise one or more LEDs 100 a attached to an upper surface of a thermal element and electrically connected to at least one electrical element. One or more ESD devices 100 b can also be attached to an upper surface of an electrical element. The thermal element can comprise a heat transfer material 72, and the electrical elements can comprise metal leads 74 a and 74 b of a leadframe. The thermal and electrical elements can be contained within a molded plastic body 76 having a reflector cavity 76 a and can comprise a thickness from an upper surface comprising the LEDs 100 a to a bottom surface 76 b of the LED package 70. A suitable amount of optically transmitting encapsulant E can fill the reflector cavity to a suitable level within the reflector cavity 76 a. Heat transfer material 72 can be electrically isolated from metal leads 74 a and 74 b by insulating portions 70 a and 70 b of body 76. Heat transfer material 72 and leads 74 a and 74 b can extend to at least one exterior lateral side 79 a of body 76 wherein the material is sheared resulting in exposed portions which can be flush with the exterior lateral side 79 a. For example, heat transfer material 72 can be sheared on the exterior lateral side 79 a of body 76 to leave exposed portion 73 flush with the surface of lateral side 79 a. Similarly, metal leads 74 a and 74 b can be sheared flush with the surface of the lateral side 79 a, resulting in exposed portions 71 a and 71 b, respectively, on lateral side 79 a. Retention notches 75 can be located on at least a second exterior lateral side 79 b of body 76 adjacent first lateral side 79 a having the sheared, exposed portions 73, 71 a, and 71 b. Retention notches 75 can improve handling of LED package 70 during processing.

FIG. 8 illustrates the bottom perspective view of the features illustrated by FIG. 7. In this embodiment, leads 74 a and 74 b extend from bottom surface 76 b which is substantially orthogonal to exterior lateral sides 79 a and 79 b of the LED package 70. That is, leads 74 a and 74 b do not comprise portions which extend beyond any lateral exterior side or any lateral exterior surface of LED package 70. As illustrated in FIGS. 9A and 9B, heat transfer material 72 can comprise a bottom surface 78 which can extend to a greater distance away from body 76 of LED package 70 than a distance from body 76 to bottom surfaces 80 a and 80 b of leads 74 a and 74 b, respectively, when package 70 is mounted to a PCB 90. That is, heat transfer material 72 can extend to have its bottom surface 78 located on a plane P1 which is lower than a plane P2 of the bottom surfaces 80 a and 80 b of leads 74 a and 74 b, respectively. In one embodiment, a suitable range in distance between P1 and P2 can be from slightly above 0 μm to greater than 100 μm. In other embodiments, a suitable range in distance between P1 and P2 can be from about 25 μm to 50 μm, 50 μm to 100 μm, or greater than 100 μm. When package 70 is mounted, for example by soldering, to a PCB 90, a gap 96 can exist between the bottom surface 78 of heat transfer material 72 and PCB 90 which can be smaller than a gap 94 existing between bottom surfaces 80 a and 80 b of leads 74 a and 74 b and the PCB 90. A more uniform and reliable thermal contact, or solder joint created between heat transfer material 72 and PCB 90, can form once solder 92 solidifies such that the thermal contact is essentially free of voids. As such, overall heat transfer, heat dissipation capability, and thermal properties of LED package 70 are improved. In addition to bottom surface 78, bottom surfaces 80 a and 80 b of leads 74 a and 74 b can also be wetted by solder 92 to form electrical contacts with PCB 90.

Also illustrated by FIG. 9B, PCB 90 can comprise an intermediate substrate disposed above a heat transfer layer 93 and a heat sink 95. Heat can dissipate away from LED package 70 by moving in a path and pass from heat transfer material 72 into solder 92 and then into PCB 90. Heat can then pass from PCB 90 and into heat transfer layer 93 which can comprise any material that is thermally conductive. Heat can continue on a path which passes from heat transfer layer 93 into heat sink 95 which can pass heat into ambient air for example. Heat sink 95 can comprise any material capable of conducting heat, and which ideally would not increase in temperature when heat is applied.

FIGS. 10A-10F illustrate side, top perspective, and bottom perspective views of a further embodiment of a light emitting diode package 120. This embodiment illustrates using another LED packaging technology utilizing methods such as low temperature co-fired ceramic (LTCC) instead of molding about lead portions from a leadframe. For example, the body can comprise an insulating member, such as a submount 122. An active layer 118 can be disposed on a top surface of the submount 122. Active layer 118 can comprise a light emitting device connected to electrical components. For example, light emitting device can comprise an LED chip 110 electrically connected to electrical components comprising an anode 114 and a cathode 112. Anode 114 and cathode 112 can comprise a metal or any other suitable electrically conductive material known in the art. LED chip 110 can optionally be coated with a phosphor for producing a desired light wavelength spectrum. Active layer 118 can be electrically and thermally connected to the body, or submount 122. Submount 122 can comprise one of many different materials including those which are electrically insulating. Suitable materials can comprise for example, ceramic materials including aluminum oxide, aluminum nitride, or organic insulating materials such as polyimide (PI) and polyphthalamide (PPA).

An optical element or lens 116 can be disposed over the top surface of the submount 122 and enclose LED 110 and at least a portion of active layer 118. Lens 116 can comprise a molded lens of any suitable size and shape for producing a desired light output. Anode 114 and cathode 112 can electrically couple to electrical elements of the LED package 120. Electrical elements can comprise first and second surface pads 124 and 128, to which anode 114 and cathode 112 can electrically connect, respectively. First and second surface pads 124 and 128 can be disposed or mounted on a bottom surface 130 of submount 122 or they can be flush with bottom surface 130. LED package 120 can further comprise a thermal element, for example a heat transfer material 126. Heat transfer material 126 can be disposed or mounted to bottom surface 130 of submount 122. Heat can dissipate from active layer 118 by extending through thermally conductive paths in submount 122. Heat transfer material 126 can comprise any thermally conductive material known in the art and can be disposed between the first and second surface pads 124 and 128.

Heat transfer material 126 can be substantially centrally and vertically aligned beneath LED chip 110. Heat transfer material 126 may not be in electrical contact with active layer 118 or first and second pads 124 and 128. Heat can pass into submount 122 directly below and around LED chip 110. Heat transfer material 126 can comprise any size and shape suitable to assist with the dissipation of heat by allowing the heat to spread where it can dissipate to an external source or substrate, for example a PCB having, for example, a heat sink. A bottom surface 132 of heat transfer material 126 can extend to a plane P1 which is further away in distance from bottom surface 130 of submount 122 than bottom surfaces of the electrical elements. For example, electrical elements can comprise first and second pads 124 and 128 having bottom surfaces 134 and 136 respectively. Bottom surfaces 134 and 136 can extend to a plane P2 that is closer in distance to bottom surface 130 of submount 122 than P1 or flush with bottom surface 130. In one embodiment, a suitable range for a distance between P1 to P2 can be from 0 μm to greater than 100 μm. In other embodiments, a suitable range for a distance between P1 and P2 can be from 25 μm to 50 μm, 50 μm to 100 μm, or greater than 100 μm. As previously described, this configuration enables adequate wetting of bottom surface 132 of heat transfer material 126 when soldered to a PCB. Improved heat dissipation and improved thermal properties of LED package 120 are thereby accomplished.

As illustrated by FIG. 10A, LED package 120 can be mounted to an external source, such as a PCB 150. PCB 150 can be an intermediate substrate located above a heat transfer layer 152 and a heat sink 154. Solder 160 can be used to attach LED package 120 to PCB 150. For example, once wetted by solder 160, any gap between the thermal element, that is, a gap 158 between bottom surface 132 of heat transfer material 126 and PCB 150 will be smaller than a gap 156 between the electrical elements, that is, the bottom surfaces 134 and 136 of respective first and second surface pads 124 and 128 and PCB 30. Having heat transfer material 126 in this configuration can increase the likelihood that solder 160 will wet the entire bottom surface 132 of heat transfer material 126 and can allow formation of an adequate thermal contact between LED package 120 and PCB 150. Upon solidification of the solder 160, the thermal contact between heat transfer material 126 and PCB 150 can comprise a solder joint that is essentially free of voids, thereby being more reliable. This can increase the likelihood of obtaining better heat transfer from heat transfer material 126 to PCB 150. For example, if LED package 120 were to be sheared from PCB 150, a footprint of the solder joint on the backside of the package and PCB 30 would preferably be essentially free of voids. A small number, or substantially zero voids indicates better wetting of the thermal element, and a better, more reliable thermal contact between heat transfer material 126 of LED package 120 and PCB 150. Bottom surface 132 of heat transfer material 126 as well as bottom surfaces 134 and 135 of portions of first and second surface pads 124 and 128, respectively are thus all wetted by solder 160 and connected to PCB 150 upon solidification of solder 160.

Referring now to FIGS. 10D, 10E and 10F, bottom surface 132 of heat transfer material 126 can comprise grooves 140 which can further improve heat dissipation of LED package 120 by breaking up small voids which may form when LED package 120 is attached to PCB 150 (FIG. 10A). As illustrated by FIG. 10D, one or more grooves 140 can be defined in bottom surface 132 of heat transfer material 126 and extend in a linear direction along a first length. Where a plurality of grooves 140 are present, they can extend parallel to one another. As illustrated by FIG. 10E, grooves 140 can extend in a linear direction along a second length which can be in a direction orthogonal with the first length. As illustrated by FIG. 10F, grooves 140 can extend in more than one direction, such as for example as shown in FIG. 10F where grooves 140 extend in two directions that can be orthogonal to one another forming a plurality of island structures that are surrounded on at least two or more, and even all four, sides by grooves 140. Grooves such as grooves 140 can extend in any suitable direction even other than the directions shown in FIGS. 10D-10F. Additionally, the island structures that can be formed between the grooves can be any suitable configuration, such as for example and without limitation, rectangular, square, circular post type configuration, or any other suitable configuration.

Embodiments of the present disclosure shown in the drawings and described above are exemplary of numerous embodiments that can be made within the scope of the appended claims. It is contemplated that the configurations of LED packages having improved solder reliability for heat transfer, and methods of making the same can comprise numerous configurations other than those specifically disclosed. 

What is claimed is:
 1. A light emitting device package, the package comprising: a body comprising at least a portion of a thermal element and at least a portion of an electrical element, the electrical element contained between lateral sides of the body without extending beyond the lateral sides of the body; at least one light emitting device mounted on a top surface of the body; and both the thermal element and the electrical element extending from a bottom surface of the body wherein a bottom surface of the electrical element extends away from the body a first distance, and a bottom surface of the thermal element extends away from the body a second distance that is greater than the first distance.
 2. The light emitting device package according to claim 1, further comprising a lens.
 3. The light emitting device package according to claim 1, wherein the second distance is greater than the first distance by from about 0 μm to about 100 μm.
 4. The light emitting device package according to claim 1, wherein the second distance is greater than the first distance by greater than about 100 μm.
 5. The light emitting device package according to claim 1, wherein the body comprises an insulating material.
 6. The light emitting device package of claim 1, wherein the electrical element extends to a first plane and the thermal element extends to a second plane which is lower than the first plane.
 7. The light emitting device package of claim 1, wherein the body comprises a reflector cavity.
 8. A light emitting device package, the package comprising: a body comprising at least a portion of a thermal element and at least a portion of an electrical element, the electrical element and the thermal element both contained between lateral sides of the body without extending beyond the lateral sides of the body; at least one light emitting device thermally connected with the thermal element; and both the thermal element and the electrical element extending from a bottom surface of the body wherein a bottom surface of the electrical element extends away from the body a first distance, and a bottom surface of the thermal element extends away from the body a second distance that is greater than the first distance.
 9. The light emitting device package according to claim 8, further comprising a lens.
 10. The light emitting device package according to claim 8, wherein the second distance is greater than the first distance by from about 0 μm to about 100 μm.
 11. The light emitting device package according to claim 8, wherein the second distance is greater than the first distance by greater than about 100 μm.
 12. The light emitting device package according to claim 8, wherein the body comprises an insulating material.
 13. The light emitting device package of claim 8, wherein the electrical element extends to a first plane and the thermal element extends to a second plane which is lower than the first plane.
 14. The light emitting device package of claim 8, wherein the body comprises a reflector cavity.
 15. A light emitting device package, the package comprising: a body comprising a first surface and a second surface; at least one light emitting device mounted on the first surface of the body; an electrical element contained between lateral sides of the body without extending beyond the lateral sides of the body, wherein at least a portion of the electrical element is exposed on the second surface of the body; the electrical element having an electrical element bottom surface that is disposed along a first plane; and a thermal element with a thermal element bottom surface that is disposed along a second plane that is different from the first plane.
 16. The light emitting device package of claim 15, wherein the portion of the electrical element exposed on the second surface is flush with the second surface.
 17. The light emitting device package of claim 15, wherein the portion of the electrical element exposed on the second surface extends away from the second surface a distance that is less than a distance the thermal element extends away from the second surface.
 18. A light emitting device package, the package comprising: a body comprising a first surface and a second surface; at least one light emitting device electrically connected to an anode and a cathode on the first surface of the body; at least one electrical element on the second surface of the body that is electrically connected to at least one of the anode and cathode; a thermal element on the second surface of the body; and wherein the at least one electrical element extends away from the second surface of the body a first distance and the thermal element extends away from the second surface of the body a second distance that is greater than the first distance. 